Can you tig weld aluminum

The oxide has a higher melting point than the aluminum itself, which is why it needs to be removed before welding. The welding machine needs to either have been built for TIG welding like these or has the necessary accessories. A foot current control is essential since heat builds up as the weld is started, requiring less heat from the electrode toward the end of the weld.

Direct current is used as a limited alternative but results in higher heat levels on the electrode and poor oxide cleaning. The torch nozzle also must have been selected for use on aluminum. When the diameter of the electrode is changed, a wider range of heat input can be used at different metal thicknesses. MIG aluminum welding is preferred for thicker pieces of metal. New aluminum alloys such as HTS offers a lower-cost method for welding aluminum. It can be used with any heat source.

The most popular welding aluminum is either pure aluminum 1xxx or an aluminum manganese alloy The repair or fabrication of aluminum is done with aluminum brazing lower cost, stronger welds , using HTS brazing rods. They are identified in a 4 digit system with the first digit indicating the metal alloyed with the aluminum:. It will give you the ability to work on any aluminum alloy no matter the condition it is in.

It works with any filler type, and it works best with your standard gas mixtures. With all of that in mind, you can still get quality welds on Aluminum with a TIG machine running direct current. Join my weekly newsletter and receive helpful tips, tools, and theories about welding and joining.

Please confirm the subscription Email in your inbox. The link is only valid for 60 minutes. But sometimes budgets, emergencies, or other circumstances beyond our control mean that we have to do the best we can with what we have. If all you have is a TIG machine with DC and you have to make a repair or get a fabrication project done, you can still make it happen. With a little bit of trial and error, a lot of patience, and the calming, cleansing effect of deep breathing, you can get it done.

There are just no two ways about it! The information above will help you get through a one-time job and back to your routine. If you liked this article, have a look at my other articles I wrote about the topic! To address some of the questions I frequently got asked or was wondering myself during my job, I started this blog. It has become a bit of a pet project, as I want to learn more about the details about welding. I sincerely hope it will help you to improve your welding results as much as it did improve mine.

A cracked wheel is undoubtedly bad news. Depending on the type and severity of the wheel crack, it can make it mildly hazardous to outright dangerous to drive your vehicle. Since most alloy wheels Welding aluminum is one of the only times that alternating current is preferred. Alternating current, or AC, flips the polarity between standard and reverse quickly, from sixty to one hundred twenty times each second.

Aluminum is usually TIG welded with alternating current. The quick polarity flips have a sandblasting effect that breaks up the surface oxides to produce a clean weld. The problem with AC welding is that the current does not penetrate deeply into the joint and produces a shallow weld. To produce a strong weld in thick aluminum with alternating current, the welding is done in steps. You have to bevel the edges of the joint, lay down a root bead, then come back with one or more passes of filler and cap welds to get a strong joint.

This requires three or four passes with the welder before the joint is complete. You can get a good, deep weld joint in one pass using DC welding.

This saves time and produces a stronger weld. DC welds are also useful for fixing deep pits and gouges in aluminum. You can quickly fill a cavity with DC welding and get a strong joint that keeps the fill in place. Once the hole has been filled, smooth the surface with a grinder, and the part is like new. This helps fix expensive, machined aluminum parts that have become slightly damaged. The best aluminum grades for this process are , , and pure aluminum everything in the series.

If you are working with other categories of aluminum, you may need to use AC to make the weld. In addition to using the right grade of aluminum, the correct dimensions are essential. DC welding puts a lot of heat into the workpiece.

If you try to DC weld thin stock, it can overheat and warp. Stick with AC for the thing stuff. Using the right equipment is important for using direct current to TIG weld aluminum. Having the right rods, electrode, and gas makes a big difference in weld quality.

Pure aluminum rods are necessary for TIG welding aluminum using direct current. These have a blue tip. Unlike AC welding, you need a sharp tip on the electrode for DC welds. Pre-sharpened rods are available, or you can sharpen it yourself with a grinder.

Standard tungsten and thoriated rods will also work. The best gas for DC welding is ultra-pure helium. It produces a hotter arc than helium-argon mixes or pure argon. The high heat from the arc helps break up the oxide layer and creates a weld that holds better. Opting for ultra-pure over standard helium guarantees that there are no contaminants in the shielding gas.

Even a little bit of oxygen mixed with the helium can cause oxidation in the weld, which leads to cracking. You need to set your welder DC, of course. You also have to reverse the polarity of the welder so that the electrode is the positive terminal, and the weld surface is the negative terminal.

Reverse polarity will create a weld puddle under the oxidized layer with the oxide floating on top. Consult the manual for your welder for recommended amperage and other settings for direct current welding. Rather than using the same amperage for the entire weld, set up the welder with a controller for variable amperage.

With variable amperage, the power level is controlled with a foot pedal or a sliding switch on the electrode torch. Variable amperage is very important for DC welding aluminum. Using fixed amperage can cause real problems with your joint.